Reusable envelope

ABSTRACT

A reusable envelope includes first, second and third panels, the first panel being joined to the second panel along a definition line and the second panel being joined to the third panel along a fold line. The second panel has a first tear line spaced from the fold line by a predetermined distance to define a first area and the third panel has a second tear line spaced from the fold line by the predetermined distance to define a second area. The first and second panels are folded along the definition line, and the second and third panels are folded along the fold line such that the first and second tear lines are collinear, the first area being sealed to the second area to define a tear strip that is removable along the collinear tear lines to at least partially create a second envelope for remailing.

RELATED APPLICATION

[0001] This application is a continuation-in-part of U.S. patentapplication Ser. No. 09/590,802, filed Jun. 9, 2000.

FIELD OF THE INVENTION

[0002] The present invention relates to a remailable or two-way envelopeadapted to be used after its first mailing to return an enclosure, suchas a payment or the like, to the original sender.

BACKGROUND OF THE INVENTION

[0003] Remailable envelopes are well known in the art and numerouspatents describe many different variations of remailable envelopes. Someexamples of paten ts showing this type of envelope include U.S. Pat. No.4,730,768 to Gendron, U.S. Pat. No. 5,251,810 to Kim and U.S. Pat. No.5,875,964 to Pham.

[0004] It has been found that the remailable en velopes of the prior arthave not received widespread commercial acceptance by manufacturers orapproval by recipients. Therefore, the applicant has developed animproved reusable mailing envelope with tear-strip opening device, asdisclosed in the above-mentioned U.S. patent application Ser. No.09/590,802, the disclosure of which is hereby incorporated by reference.It is an object of the present invention to provide a furtherdevelopment of this reusable mailing envelope that may include one ormore panels bearing printed information constituting contents of theenvelope.

[0005] Thus, it is an object of the present invention to provide areusable envelope that can be quickly and easily opened and provides areturn envelope that is easy for the recipient to use.

[0006] It is another object of the present invention to provide areusable envelope that can be quickly and easily opened to reveal atleast one printed panel, and provides a return envelope that is easy forthe recipient to use.

[0007] It is also an object of the present invention to provide areusable envelope that is relatively simple in construction as comparedto those of the prior art, that is inexpensive to manufacture onexisting production machines, and that can be used both in themanufacture of direct mail articles to produce remailing envelopes intowhich enclosures are placed by the recipient.

[0008] It is a further purpose of the present invention to provide aneasy-opening envelope that provides rapid access to the printed panelsand to the enclosures without the possibility of damaging either theprinted panels or the enclosures.

SUMMARY OF THE INVENTION

[0009] In accordance with one aspect of the present invention, theimproved reusable envelope includes a plurality of panels including atleast a first flap panel, a front panel and a rear panel, each beinggenerally rectangular and at least the first flap panel and the frontpanel being similar in size, the first flap panel being joined to thefront panel along a first transverse definition line and the rear panelbeing joined to the front panel along a first transverse fold line.

[0010] A generally rectangular second flap panel is joined to the rearpanel along a second transverse fold line, the second flap panel havinga first transverse edge. The first flap panel has a second transverseedge opposed to the first definition line and a first transverseweakened tear line spaced from the second transverse edge, the rearpanel has a second transverse weakened tear line spaced from the firsttransverse fold line by a first distance, and the front panel has athird transverse weakened tear line spaced from the first transversefold line by the first distance. The first tear line on the first flappanel is spaced from the second edge by no more than the first distance.

[0011] The rear panel is folded with respect to the front panel alongthe first transverse fold line, and the first flap panel is folded withrespect to the front panel along the first transverse definition line,such that the first, second and third tear lines are collinear to formthe reusable envelope for a first mailing. A tear strip is formed of atleast three areas consisting of an area on the first flap panel betweenthe second transverse edge and the first transverse tear line, an areaon the front panel between the third transverse tear line and the firsttransverse fold line, and an area on the rear panel between the firsttransverse fold line and the second transverse tear line.

[0012] A first adhesive area is provided separate from the tear stripfor sealing the front panel to the rear panel to form an envelope pocketenclosed within the reusable envelope, and a second adhesive area isalso provided, wherein after the tear strip has been removed along thecollinear tear lines, the envelope pocket has an open top at the secondtransverse fold line, and the second flap panel is sealable to the rearpanel by the second adhesive area for closing the top of the envelopepocket to form a second envelope for a second mailing.

[0013] In accordance with another aspect of the present invention, areusable envelope includes a plurality of panels including first, secondand third panels each being generally rectangular and at least thesecond and third panels being similar in size, the first panel beingjoined to the second panel along a transverse definition line and thesecond panel being joined to the third panel along a transverse foldline.

[0014] The second panel has a first transverse weakened tear lineextending entirely across the second panel and spaced from the fold lineby a predetermined distance to define a first area from the first tearline to the fold line, and the third panel has a second transverseweakened tear line extending entirely across the third panel and spacedfrom the fold line by the predetermined distance to define a second areafrom the second tear line to the fold line.

[0015] The first panel is folded with respect to the second panel alongthe definition line, and the second panel is folded with respect to thethird panel along the fold line such that the first and secondtransverse tear lines are collinear, the first area being sealed to thesecond area to define a tear strip that is removable along the collineartear lines to at least partially create a second envelope for remailing.

[0016] In accordance with a further aspect of the present invention, oneor more contents panels may be joined at either the top or bottom edgeof the reusable envelope before folding.

[0017] These and other objects, aspects and features of the presentinvention will become apparent from the following detailed descriptionof the preferred embodiments taken in conjunction with the attacheddrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0018]FIG. 1 is a front view of a blank of a reusable envelope inaccordance with a first preferred embodiment of the present invention.

[0019]FIG. 2 is a front view of a blank of a reusable envelope inaccordance with a second preferred embodiment of the present invention.

[0020]FIG. 3 is a front view of the reusable envelope of FIG. 1 afterfolding.

[0021]FIG. 4 is a front view of the reusable envelope of FIG. 2 afterfolding.

[0022]FIG. 5 is a front view of a blank of a reusable envelope inaccordance with a third preferred embodiment of the present invention.

[0023]FIG. 6 is a front view of a blank of a reusable envelope inaccordance with a fourth preferred embodiment of the present invention.

[0024]FIG. 7 is a back view of the blank of FIG. 1.

[0025]FIG. 8 is a back view of the reusable envelope of FIG. 1 afterfolding.

[0026]FIG. 9 is a view of the folded configuration of FIG. 3.

[0027]FIG. 10 is a view of a folded configuration of the envelope ofFIG. 5.

[0028]FIG. 11 is a view of a folded configuration of the envelope ofFIG. 6.

[0029]FIG. 12 is a front view of a blank of a reusable envelope inaccordance with a fifth preferred embodiment of the present invention.

[0030]FIG. 13 is a front view of a blank of a reusable envelope inaccordance with a sixth preferred embodiment of the present invention.

[0031]FIG. 14 is a front view of the reusable envelope of FIG. 12 afterfolding.

[0032]FIG. 15 is a front view of the reusable envelope of FIG. 13 afterfolding.

[0033]FIG. 16 is a front view of a blank of a reusable envelope inaccordance with a seventh preferred embodiment of the present invention.

[0034]FIG. 17 is a front view of a blank of a reusable envelope inaccordance with a eighth preferred embodiment of the present invention.

[0035]FIG. 18 is a back view of the blank of FIG. 12.

[0036]FIG. 19 is a back view of the reusable envelope of FIG. 12 afterfolding.

[0037]FIG. 20 is a view of the folded configuration of FIG. 15.

[0038]FIG. 21 is a view of a folded configuration of the envelope ofFIG. 16.

[0039]FIG. 22 is a view of a folded configuration of the envelope ofFIG. 17.

[0040]FIG. 23 is a front view of a blank of a reusable envelope inaccordance with a ninth preferred embodiment of the present invention.

[0041]FIG. 24 is a front view of a blank of a reusable envelope inaccordance with a tenth preferred embodiment of the present invention.

[0042]FIG. 25 is a front view of the reusable envelope of FIG. 23 afterfolding.

[0043]FIG. 26 is a front view of the reusable envelope of FIG. 24 afterfolding.

[0044]FIG. 27 is a front view of a blank of a reusable envelope inaccordance with a eleventh preferred embodiment of the presentinvention.

[0045]FIG. 28 is a back view of the blank of FIG. 23.

[0046]FIG. 29 is a back view of the reusable envelope of FIG. 23 afterfolding.

[0047]FIG. 30 is a view of a folded configuration of the envelope ofFIG. 23.

[0048]FIG. 31 is a view of a folded configuration of the envelope ofFIG. 27.

[0049]FIG. 32 is a front view of a blank of a reusable envelope inaccordance with a twelfth preferred embodiment of the present invention.

[0050]FIG. 33 is a view of a folded configuration of the envelope ofFIG. 32.

[0051]FIG. 34 is an explanatory view of certain key features of oneaspect of the present invention.

[0052]FIG. 35 is a view of a development of FIG. 34.

[0053]FIG. 36 is an explanatory view of certain key features of anotheraspect of the present invention.

[0054]FIG. 37 is a view of a development of FIG. 36.

[0055]FIG. 38 is a view of a folded configuration of a development ofFIG. 33.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0056] A pre-cut blank 1 is used to construct the original reusableenvelope 10 according to the present invention, as shown in FIGS. 1 and7. As used herein, the letter “A” will refer to the exterior face andthe letter “B” will refer to the interior face. The blank 1 is typicallyformed from a web or larger sheet of suitable envelope grade material inaccordance with methods well-known in the art. The blank 1 includes anaddress or first flap panel 12, a rear panel 14 and a front panel 16.Panels 12 and 16 are integrally joined along a transverse definitionline 18 which, in this embodiment, is a weakened parting line. In apreferred embodiment, parting line 18 is a line of perforations, beingeither slit or hole perforations. All other parting lines in thefollowing description are also preferably lines of slit or holeperforations.

[0057] Panels 14 and 16 are integrally joined along a transverse foldline 20. In this embodiment, the panels 12, 14 and 16 are of a similarsize and are generally rectangular in shape.

[0058] A second flap panel 22 is integrally joined to rear panel 16along a fold line 24. The second flap panel 22 advantageously has thesame width (transverse direction) as the other panels, but is shorter(lengthwise direction).

[0059] As shown in FIGS. 1 and 7, a plurality of other weakened partinglines divide the panels 12, 14, 16 and 22 into different functionalportions. First flap panel 12 is provided with a transverse weakenedparting line 26 parallel to its top edge 28 and spaced therefrom by afirst distance. As used herein, the edge of a panel can mean either afree edge or a fold or parting line delimiting the panel.

[0060] Front panel 16 is provided with a transverse weakened partingline 30 parallel to fold line 20 and spaced therefrom by the firstdistance, and rear panel 14 is provided with a transverse weakenedparting line 32 parallel to fold line 20 and spaced therefrom by thefirst distance.

[0061] As described below, the combination of fold line 20 with partinglines 30 and 32 at a central portion of the blank 1, rather than at anedge thereof, enables a novel and advantageous tear strip constructionfor opening the reusable envelope 10 to form the second envelope forremailing.

[0062] Running the entire length of the blank are left and rightweakened parting lines 34 and 36. Left parting line 34 is parallel tothe left edge 38 and is spaced therefrom by a second distance.Correspondingly, right parting line 36 is parallel to the right edge 40and spaced therefrom by the second distance. Preferably, the firstdistance is equal to the second distance.

[0063] These lines define areas on the exterior side A of the blank 1,as shown in FIG. 1. Of particular relevance here, area 42 extendsentirely across the width of first flap panel 12 from top edge 28 toparting line 26, area 44 extends entirely across the width of frontpanel 16 from parting line 30 to fold line 20, and area 46 extendsentirely across the width of rear panel 14 from fold line 20 to partingline 32.

[0064] In addition, on the left side of the blank 1, area 48 extendsfrom top to bottom between left edge 38 and left parting line 34, witharea 50 being the lower portion thereof from fold line 24 to bottom edge52.

[0065] These left side areas are mirror-imaged on the right side of theblank 1. Thus, area 54 extends from top to bottom between right edge 40and right parting line 36, with area 56 being the lower portion thereoffrom fold line 24 to bottom edge 52.

[0066] As shown in FIG. 1, areas 50 and 56 are provided with a firstadhesive 58 for sealing the reusable envelope 10. The first adhesive 58in one or both areas can be of the type that is sealed when the reusableenvelope 10 is manufactured. Alternatively, the first adhesive 58 can bea remoistenable adhesive, so that the reusable envelope 10 can bemanufactured without being sealed shut, and can thereafter be sealed forthe first mailing at the user's convenience.

[0067]FIG. 1 illustrates the first adhesive 58 as filling the entiretyof the areas 50 and 56. However, it will be understood that this and anyother adhesive employed in the present invention can fill less than allof the indicated area, or it may be used in a spot welding fashion asdesired.

[0068]FIG. 7 illustrates the interior face B of the blank 1, opposite tothe exterior face A illustrated in FIG. 1, and therefore the referencenumerals appear reversed from left to right. Interior face B includesthe transverse parting lines 18, 26 30 and 32 and the lengthwise partinglines 34 and 36.

[0069] The interior face B also includes, on the rear panel 14B, line 60running the entire width parallel to bottom edge 52 and spaced therefromby the first distance. Fold line 24 is parallel to line 60 and spacedtherefrom by the first distance. Area 64 is from left to right betweenline 60 and bottom edge 52.

[0070] On the front panel 16B, side lines 66 and 68 and bottom line 70are provided. These lines define a U-shaped area comprised of threeareas that will form the side and bottom edges of a second envelope forthe second mailing. Area 72 extends from left parting line 34 to leftside line 66 and from parting line 18 to bottom line 70. Area 74 extendsfrom right parting line 36 to right side line 68 and from parting line18 to bottom line 70. Area 76 extends from left parting line 34 to rightparting line 38 and from bottom line 70 to parting line 30.

[0071] In addition, area 78 extends from top edge 28 to fold line 20 andfrom left edge 38 to left parting line 34, while area 80 extends fromtop edge 28 to fold line 20 and from right edge 40 to right parting line36.

[0072] As shown in FIG. 7, areas 42, 46, 78 and 80 are provided with thefirst adhesive 58 for sealing the reusable envelope 10, and areas 72, 74and 76 are provided with the first adhesive 58 to create the second,smaller envelope for remailing.

[0073] Area 64 on the interior face B of the blank is provided with aremoistenable adhesive 82 so as to be used to seal the second envelope.

[0074] In the manufacture of the original reusable envelope 10 of theinvention for its first mailing, the remoistenable adhesive 82 isapplied to area 64, where it dries without bonding to other areas. Thenthe first adhesive 58 is applied to areas 50 and 56 on the exterior faceA and areas 42, 46, 72, 74, 76, 78 and 80 on the interior face B. Theblank is folded along fold line 24 so that the second flap panel 22 isfolded with respect to the rear panel 14. As used herein, when one panelis described as being folded with respect to another panel, it meansthat the panels overlie each other in parallel. There may or may not beother panels between the two referenced panels, and the inner or outersurfaces of the two referenced panels may face each other. For example,in this embodiment the folding of the second flap panel 22 with respectto the rear panel may place second flap panel 22A on rear panel 14A.

[0075] The blank 1 is also folded along fold line 20 so that the rearpanel 14 is folded with respect to the front panel 16, for example toplace rear panel 14B on front panel 16B. In addition, the blank 1 isfolded along fold line 18 so that the rear panel 14 is folded withrespect to the first flap panel 12, for example to place rear panel 14Aon first flap panel 12B.

[0076] A view of the front of the reusable envelope 10 at this stage ofmanufacture is shown in FIG. 3, and a view of its back is shown in FIG.8. FIG. 9 is a cross-sectional view of FIG. 3 showing how the panels maybe arranged as folded.

[0077] While FIG. 9 illustrates second flap panel 22 between first flappanel 12 and rear panel 14, second flap panel 22 could alternatively bebetween rear panel 14 and front panel 16.

[0078] Moreover, since the rear panel 14 has substantially the samelength as the first flap panel 22 and the front panel 16, the bottomfold includes all four panels in this embodiment. However, the rearpanel 14 may be shorter in the lengthwise direction so that it and thesecond flap panel 22 are not in the fold.

[0079] The first flap panel 12 may also alternatively be somewhatshorter than the front panel 16, provided that it is long enough to haveits area forming part of the first tear strip 84. That is, in FIG. 9,the first flap panel 12 would not extend upward all the way to be levelwith the fold line 20, but would extend above the dotted line.

[0080] Each tear strip may be formed of the entire area between therespective lines, or may be formed of only a portion of the entire area.

[0081] Following each folding step in the manufacturing process, orafter some or all of the folding steps, the reusable envelope 10 ispassed through perforating apparatus, e.g. a perforating wheel, tosimultaneously form the parting lines as lines of perforation and tobond the areas bearing the first adhesive 58 to the respective opposingareas to seal the reusable envelope 10 in its closed form.

[0082] The result is the formation of three tear strips sealing thereusable envelope 10 closed for its first mailing. As shown in FIGS. 3,8 and 9, top tear strip 84 is formed of, in order from the front face tothe back face of the folded envelope, areas 42A, 42B, 46A, 46B, 44B and44A. Left tear strip 86 is formed of area 48 running the entire lengthof the blank 1 and right tear strip 88 is formed of area 54 running theentire length of the blank 1.

[0083] As shown in FIG. 1, first flap panel 12A includes an addressarea, a return address area and a postage area, which appear on thefront of the folded reusable envelope 10 in FIG. 3. Rear panel 14Aincludes a second address area, a second return address area and asecond postage area, which are inside the folded reusable envelope 10and therefore not visible during the first mailing.

[0084] To open the reusable envelope 10, the three tear strips 84, 86and 88 are removed along the parting lines 26, 34 and 36. Upon removalof the three tear strips, the first flap panel 12 is detachable from thefront panel 16 along parting line 18, and the smaller second enveloperemains, extending from parting line 18 to parting line 26 and from leftparting line 34 to right parting line 38. Because the first flap panel12 has been removed, the exterior face of the rear panel 14A is nowexposed, bearing the second address and postage areas. This secondenvelope is sealed along its lower edge by area 76, along its left edgeby area 72 and along its right edge by area 74. The opening of thesecond envelope is where parting line 18 lies along fold line 24.

[0085] In order to use the second envelope for the second mailing, ifmaterials are to be returned to the sender, the recipient inserts thematerials into the second envelope. Then the adhesive 82 on the area 64is moistened, and the second flap panel 22 is folded along fold line 24to adhesively secure the second flap panel face 22B to the rear panelface 16A. The recipient completes the second return address area andattaches the proper postage.

[0086] Alternatively, the original sender can provide the recipient'sreturn address by computer-directed printing means at the time that theenvelope blank is printed, die-cut and assembled. Return postage indiciacan also be preprinted on rear panel 14 by the originator.

[0087] As shown by the dotted line in FIG. 9, the top tear strip 84includes the area 42 at the edge of first flap panel 12 and areas 44 and46 at a central portion of the blank 1, i.e. between front panel 16 andrear panel 14 on either side of fold line 20. In prior envelopes, anytear strips have been formed only from edge portions of the blanks, notbetween panels of similar size and not between panels that will form asecond envelope for remailing. In contrast, in accordance with thepresent invention, the tear strip structure can exist between the panelsthat will form the second envelope. By sealing the areas 44 and 46, thetear strip 84 is sturdier and easier to remove without ripping theremaining panels.

[0088]FIG. 2 illustrates another preferred embodiment of an envelope 110in accordance with the present invention. In this embodiment, the rearpanel 114 has four slit lines 101, 103, 105 and 107 defining the sidesof the second envelope. Left fold line 109 between slit lines 101 and103 and right fold line 111 between slit lines 105 and 107 are notperforated. Either the exterior or interior surface of area 113 betweenslit lines 101 and 103 and between left edge 38 and left fold line 109,and either the exterior or interior surface of area 115 between slitlines 105 and 107 and between right edge 40 and right fold line 111 areprovided with the first adhesive 58, as are areas 50 and 56. However,what would otherwise be areas 72 and 74 on the interior face B are notprovided with the first adhesive 58.

[0089] When the reusable envelope 110 in this embodiment is folded intoits original form, as shown in FIG. 4, it appears to be identical to thefirst reusable envelope 10. However, in forming the reusable envelope110, the areas 113 and 115 are first folded in, so that they form thesides of the second envelope.

[0090]FIGS. 5 and 6 show two other preferred embodiments whereinadditional panels are provided to carry printed information, therebyeliminating the need for separate enclosures. As shown in FIG. 5, whichshows the exterior face A of an envelope 210, the cut blank includes thesame first flap panel 12, rear panel 14 and front panel 16. However, thesecond flap panel 222, with the same areas bearing the first adhesive 58and the remoistenable adhesive 82 as second flap panel 22 in the firstembodiment, does not end in a free edge. Instead, the lower edge is adefinition line 219, here a parting line, to which one or more contentspanels 217 a-d are provided in sequence. The contents panels 217 carrythe information that other envelopes have required on separateenclosures, such as a letter to the customer on contents panels 217 a-cand a payment coupon on contents panel 217 d.

[0091] Each of the contents panels 217 has a length that is less thanthat of the first flap panel 12, so that the contents panels 217 willfit entirely within the envelope 210 when it is folded and sealed. Thefirst contents panel 217 a is connected to the second flap panel 222 atthe parting line 219, and the remaining contents panels 217 b-d can beconnected in sequence at definition lines, which can be either foldlines or parting lines, depending on the type of information printedthereon. Side areas 221 on alternate ones of the contents panels 217 areprovided with the first adhesive 58 to ensure that the envelope 210 issealed closed when folded.

[0092] The contents panels 217 are accordion folded into the envelope210 during the assembly process, using, for example, the foldedconfiguration illustrated in crossection in FIG. 10. Upon the removal ofthe three tear strips, the contents panels 217 may remain connected toeach other, but can be separated along any parting lines providedtherebetween.

[0093] In order to reuse the reusable envelope 210, the same steps aretaken as set forth above, except that here the enclosures may include,for example, a payment coupon printed on one of the information panels217 d and detached along a parting line for insertion into the secondenvelope.

[0094]FIG. 6 illustrates a variation of the envelope of FIG. 5. Theenvelope 310 of FIG. 6 is similar to envelope 210 of FIG. 5, except thatthe contents panels 317 are connected to what would otherwise be the topedge 28 of the first flap panel 312 along a definition line 323, here afold line. Parting lines 325 and 327 combine with the fold line 323 toform another of the advantageous tear strip configurations of thepresent invention. When the envelope 310 is folded, the parting line 325is collinear with the parting line 30 and the parting line 327 iscollinear with the parting line 32, so that the areas between partinglines 325 and 327 form part of the transverse first tear strip (84 inFIG. 3).

[0095] To ensure that the envelope 310 is sealed closed when folded,side areas 321 and an area 329 on the bottom of the first contents panel317a are provided with the first adhesive 58.

[0096] The contents panels 317 are accordion folded into the envelope310 during the assembly process, using, for example, the foldedconfiguration illustrated in FIG. 11. Upon the removal of the three tearstrips, the contents panels 317 may remain connected to each other, butcan be separated along any parting lines provided therebetween.

[0097]FIGS. 12 and 18 illustrate the exterior face A and interior face Bof a further development of the envelope 10 of FIGS. 1 and 4. Here, theenvelope 410 is identical to envelope 10 except for the provision of twoadditional parting lines 431, 433 extending entirely across the width.Parting line 431 is on front panel 416A at the position of whatotherwise would be bottom line 70 (see FIG. 7), and parting line 433 ison rear panel 414A parallel to parting line 32 and spaced therefrom bythe first distance. The interior face B is shown in FIG. 18, and bearsthe first adhesive 58 in the same physical areas. The foldedconfiguration of envelope 410 is shown in FIG. 20.

[0098] The front of the envelope 410 when folded is shown in FIG. 14,and appears identical to the front of envelope 10 in FIG. 3. However, asshown in FIG. 19, the back of the envelope 410 bears the additionalparting line 431. The additional parting lines 431, 433 define a fourthtear strip 484 that enables the smaller envelope to be opened after thesecond mailing.

[0099] The embodiment of FIG. 13 corresponds to the embodiment of FIG.12 in the same way as the embodiment of FIG. 2 corresponds to theembodiment of FIG. 1, i.e. it is identical, with additional partinglines 431, 533, except the provision of the slit lines 103-109 and thechange in the areas bearing the first adhesive 58. The front of thefolded envelope 510 is shown in FIG. 15.

[0100] The embodiment of FIG. 16 corresponds to the embodiment of FIG.12 in the same way as the embodiment of FIG. 5 corresponds to theembodiment of FIG. 1. Specifically, the reusable envelope 610 of FIG. 16contains the additional parting lines 431, 433 and the additionalcontents panels 217 connected to the second flap panel 22. The foldedconfiguration of the envelope 610 is shown in FIG. 21.

[0101] The embodiment of FIG. 17 corresponds to the embodiment of FIG.12 in the same way as the embodiment of FIG. 6 corresponds to theembodiment of FIG. 1. Specifically, the reusable envelope 710 of FIG. 17contains the additional parting lines 431, 433 and the additionalcontents panels 317 connected at the top to the front panel 312. Thefolded configuration of envelope 710 is shown in FIG. 22.

[0102]FIGS. 23 and 28 illustrate the exterior face A and interior face Bof a another development of the envelope 10 of FIGS. 1 and 7. Here, theenvelope 810 differs from envelope 10 in that the rear panel 814 withthe attached second flap panel 822 is at the top of the blank, and thefirst flap panel 812 is at the bottom. To accommodate this structure, atear strip configuration in accordance with the present invention isprovided between panels 814 and 816, and another such tear stripconfiguration is provided between panels 816 and 812.

[0103] Thus, definition line 818 between first flap panel 812 and frontpanel 816 is a fold line, as opposed to FIG. 1's parting line 18 betweenfirst flap panel 12 and front panel 16. A parting line 835 extendsacross the width of front panel 816 parallel to the fold line 818 andspaced therefrom by the first distance, and parting line 837 extendsacross the width of first flap panel 812 parallel to the fold line 818and spaced therefrom by the first distance.

[0104] As in the embodiment of FIG. 1, fold line 20 and parting lines30, 32 define the tear strip configuration between rear panel 814 andfront panel 816.

[0105] The first adhesive 58 is provided only in the interior face B, asshown in FIG. 28. As shown in FIG. 28 as compared with FIG. 7, anadditional area 841 extending across the entire width between fold line818 and parting line 835 also contains the first adhesive 58. On theother hand, the upper corner areas 843, 845 of the first flap panel 812Bare not provided with the first adhesive 58.

[0106] The front of the reusable envelope 810 when folded is shown inFIG. 25, and the back is shown in FIG. 29. The folded configuration ofenvelope 810 is shown in FIG. 30. As shown in these drawings, thereusable envelope 810 includes a top tear strip 884, side tear strips886, 888 and bottom tear strip 890. As shown by the lower dotted line inFIG. 30, the top tear strip 884 includes the area 842 at the edge offirst flap panel 812 and areas 844 and 846 at a central portion of theblank, i.e. between front panel 816 and rear panel 814 on either side offold line 20.

[0107] As shown by the upper dotted line in FIG. 30, the bottom tearstrip 890 includes areas at another central portion of the blank, i.e.area 841 on the front panel 816 between parting line 835 and fold line818, and an area 847 on first flap panel 812 between fold line 818 andparting line 837.

[0108] However, in accordance with an advantageous feature of thisembodiment, the rear panel 814 is shorter than the first flap panel 812and the front panel 816, so that no area of the rear panel 814 or thesecond flap panel 822 forms part of the bottom tear strip 890. Rather,these panels are completely enclosed in the reusable envelope 801, butare free within the enclosed pocket.

[0109] The embodiment of FIG. 24 corresponds to the embodiment of FIG.23 in the same way as the embodiment of FIG. 2 corresponds to theembodiment of FIG. 1, i.e. it contains the cut lines 101-107. FIG. 26shows the front face of envelope 910, which differs from that of FIG. 25in the formation of the side tear strips 986, 988 with the folding ofthe side areas along the cut lines 101-107.

[0110] The embodiment of FIG. 27 corresponds to the embodiment of FIG.23 in the same way as the embodiment of FIG. 6 corresponds to theembodiment of FIG. 1, i.e. it contains the additional contents panels217 connected to the rear panel 814, here at the top. The foldedconfiguration of envelope 1010 is shown in FIG. 31.

[0111] The embodiment of FIG. 32 corresponds to the embodiment of FIG.23 in the same way as the embodiment of FIG. 5 corresponds to theembodiment of FIG. 1, i.e. it contains the additional contents panels317 connected to the first flap panel 812, here at the bottom. Thefolded configuration of envelope 1110 is shown in FIG. 33.

[0112] Alternatively, FIG. 38 illustrates in cross-section the tearstrips at the top and bottom of the reusable envelope if the contentspanels have the same length as the other panels and are included in thetear strips.

[0113] In summary and using reference numerals from the drawings forease of understanding, a reusable envelope(10;110;210;310;410;510;610;710;810;910;1010;1110) in accordance withthe present invention includes:

[0114] a plurality of panels including at least a first flap panel(12;312;812), a front panel (16;416;816) and a rear panel(14;414;514;814), each being generally rectangular and at least thefirst flap panel (12;312;812) and the front panel (16;416;816) beingsimilar in size, the first flap panel (12;312;812) being joined to thefront panel (16;416;816) along a first transverse definition line(18;818) and the rear panel (14;414;514;814) being joined to the frontpanel (16;416;816) along a first transverse fold line (20);

[0115] a generally rectangular second flap panel (22;222;822;922) joinedto the rear panel (14;414;514;814) along a second transverse fold line(24), the second flap panel (22;222;822;922) having a first transverseedge (52;219);

[0116] the first flap panel (12;312;812) having a second transverse edge(28,323) opposed to the first definition line (18;818) and a firsttransverse weakened tear line (26) spaced from the second transverseedge (28;323);

[0117] the rear panel (14;414;514;814) having a second transverseweakened tear line (32) spaced from the first transverse fold line (20)by a first distance, the first transverse weakened tear line (26) spacedfrom the second transverse edge (28;323) by no more than the firstdistance;

[0118] the front panel (16;416;816) having a third transverse weakenedtear line (30) spaced from the first transverse fold line (20) by thefirst distance;

[0119] wherein the rear panel (14;414;514;814) is folded with respect tothe front panel (16;416;816) along the first transverse fold line (20),and the first flap panel (12;312;812) is folded with respect to thefront panel (16;416;816) along the first transverse definition line(18;818) such that the first, second and third tear lines are collinearto form the reusable envelope for a first mailing, and

[0120] wherein a tear strip (84;884) is formed of at least three areasconsisting of an area (42;842) on the first flap panel (12;312;812)between the second transverse edge (28;323) and the first transversetear line (26), an area (44;844) on the front panel (16;416;816) betweenthe third transverse tear line (30) and the first transverse fold line(20), and an area (46;846) on the rear panel (14;414;514;814) betweenthe first transverse fold line (20) and the second transverse tear line(32),

[0121] a first adhesive area (72, 74, 76) separate from the tear stripfor sealing the front panel (16;416;816) to the rear panel(14;414;514;814) to form an envelope pocket enclosed within the reusableenvelope; and

[0122] a second adhesive area (64),

[0123] wherein after the tear strip has been removed along the collineartear lines, the envelope pocket has an open top at the second transversefold line (24), and the second flap panel (22;222;822;922) is sealableto the front panel (16) by the second adhesive area (64) for closing thetop of the envelope pocket to form a second envelope for a secondmailing.

[0124] To further assist in understanding this aspect of the presentinvention, FIG. 34 identifies certain key elements of the embodimentshown in FIG. 1, which are, from top to bottom, the second edge (SE),the first tear line (FTL), the first flap panel (FFP), the definitionline (DL), the front panel (FP), the third tear line (TTL), the firstfold line (FFL), the second tear line (STL), the rear panel (RP), thesecond fold line (SFL), the second flap panel (SFP) and the first edge(FE).

[0125]FIG. 35 illustrates a further development in which the definitionline is a third fold line (TFL) between fourth and fifth tear lines(FoTL, FiTL) to form a tear strip between the first flap panel and thefront panel.

[0126] In accordance with a further aspect of the present invention, areusable envelope (10; 110;210;310;410;510;610;710;810;910; 1010; 1110)includes:

[0127] a plurality of panels including first (12;312;812), second(16;416;816) and third (14;414;514;814) panels each being generallyrectangular and at least the first (12;312;812) and second (16;416;816)panels being similar in size,

[0128] the first panel (12;312;812) being joined to the second panel(16;416;816) along a transverse definition line (18;818) and the secondpanel (16;416;816) being joined to the third panel (14;414;514;814)along a transverse fold line (20),

[0129] the second panel (16;416;816) having a first transverse weakenedtear line (30) extending entirely across the second panel and spacedfrom the fold line (20) by a predetermined distance to define a firstarea (44;844) from the first tear line (30) to the fold line (20), and

[0130] the third panel (14;414;514;814) having a second transverseweakened tear line (32) extending entirely across the third panel andspaced from the fold line (20) by the predetermined distance to define asecond area (46;846) from the second tear line (32) to the fold line(20),

[0131] wherein the first panel (12;312;812) is folded with respect tothe second panel (16;416;816) along the definition line (18;818), and

[0132] wherein the second panel (16;416;816) is folded with respect tothe third panel (14;414;514;814) along the fold line such that the firstand second transverse tear lines (30, 32) are collinear, the first area(44;844) being sealed to the second area (46;846) to define a tear strip(84;844) that is removable along the collinear tear lines to at leastpartially create a second envelope for remailing.

[0133] To further assist in understanding this aspect of the presentinvention, FIG. 36 identifies certain key elements of the embodimentshown in FIG. 12, which are, from top to bottom, the edge (SE), thefirst panel (FP), the definition line (DL), the second panel (SP), thethird tear line (TTL), the first tear line (FTL), the fold line (FL),the second tear line (STL), the fourth tear line (FOTL) and the thirdpanel (TP).

[0134]FIG. 37 illustrates a further development in which the definitionline is a fold line (FL) between additional tear lines (TL1, TL2) toform a tear strip between the first and second panels.

[0135] It will be noted that the various features of the differentembodiments, e.g. the contents panels, the side cut lines, the tearstrip configurations, the lengths of the panels, may be combined in anydesired fashion or omitted to achieve a reusable envelope in aparticular advantageous configuration in accordance with the presentinvention.

[0136] In the production of the envelopes in accordance with the presentinvention, it is preferable to form the perforations after the variouspanels have been glued and folded in superimposed position so that theperforations are aligned to thereby ensure an even and clean tear line.

[0137] While the fundamental novel features of the invention have beenshown and described, it should be understood that various substitutions,modifications and variations may be made by those skilled in the art,without departing from the spirit or scope of the invention.Accordingly, all such modifications or variations are included in thescope of the invention as defined by the claims that follow.

I claim:
 1. A reusable envelope comprising: a plurality of panelsincluding at least a first flap panel, a front panel and a rear panel,each being generally rectangular and at least the first flap panel andthe front panel being similar in size, the first flap panel being joinedto the front panel along a transverse definition line and the rear panelbeing joined to the front panel along a transverse first fold line; agenerally rectangular second flap panel joined to the rear panel along atransverse second fold line, the second flap panel having a transversefirst edge; the first flap panel having a transverse second edge and atransverse first weakened tear line spaced from the second edge; therear panel having a transverse second weakened tear line spaced from thefirst fold line by a first distance, the first tear line on the firstflap panel being spaced from the second edge by no more than the firstdistance; the front panel having a transverse third weakened tear linespaced from the first fold line by the first distance, wherein the rearpanel is folded with respect to the front panel along the first foldline, and the first flap panel is folded with respect to the front panelalong the definition line, such that the first, second and third tearlines are collinear to form the reusable envelope for a first mailing,and wherein a tear strip is formed of at least three areas including anarea on the first flap panel between the second edge and the first tearline, an area on the front panel between the third tear line and thefirst fold line, and an area on the rear panel between the first foldline and the second tear line; a first adhesive area separate from thetear strip for sealing the front panel to the rear panel to form anenvelope pocket within the reusable envelope; and a second adhesivearea, wherein after the tear strip has been removed along the collineartear lines, the envelope pocket has an open top at the second fold line,and the second flap panel is sealable to the front panel by the secondadhesive area for closing the top of the envelope pocket to form asecond envelope for a second mailing.
 2. The reusable envelope of claim1, wherein the first adhesive area is filled entirely with an adhesive.3. The reusable envelope of claim 1, wherein the second adhesive area isfilled entirely with an adhesive.
 4. The reusable envelope of claim 1,wherein the first flap panel and the front panel are equal in alengthwise direction and the first tear line on the first flap panel isspaced from the second edge by the first distance.
 5. The reusableenvelope of claim 1, where the first flap panel is shorter in alengthwise direction than the first flap panel by less than the firstdistance and the first tear line on the first flap panel is spaced fromthe second edge by less than the first distance.
 6. The reusableenvelope of claim 1, wherein the area on the first flap panel formingpart of the tear strip bears an adhesive for sealing the reusableenvelope for the first mailing.
 7. The reusable envelope of claim 6,wherein the area on the first flap panel forming part of the tear stripis filled entirely with the adhesive.
 8. The reusable envelope of claim6, wherein the adhesive is a remoistenable adhesive.
 9. The reusableenvelope of claim 1, further comprising: opposed left and right lateraldefinition lines extending from the second edge of the first flap panelto the first edge of the second flap panel, the left lateral definitionline being spaced from left lateral edges of at least the first flap andrear panels by a second distance, and the right lateral definition linebeing spaced from right lateral edges of at least the first flap andrear panels by the second distance, wherein a second tear strip isformed of at least areas on the first flap and rear panels between therespective left lateral edges and the left lateral definition line,wherein a third tear strip is formed of at least areas on the first flapand rear panels between the respective right lateral edges and the rightlateral definition line, and wherein at least the first flap and rearpanels are joined along their lateral edges to form the reusableenvelope.
 10. The reusable envelope of claim 9, wherein each of the leftand right lateral definition lines is a weakened tear line.
 11. Thereusable envelope of claim 9, wherein the rear panel includes first andsecond left transverse cut lines each extending from the left lateraledge to the left lateral definition line and first and second righttransverse cut lines each extending from the right lateral edge to theright lateral definition line, wherein each of the left and rightlateral definition lines is respectively formed of a first weakened tearline portion from the second edge to the respective first cut line, asecond weakened tear portion from the respective second cut line to thefirst edge and a fold line portion from the respective first cut line tothe respective second cut line, wherein an area from the left lateraledge to the left fold line portion and from the first left cut line tothe second left cut line forms a left side flap separate from the secondtear strip, and wherein an area from the right lateral edge to the rightfold line portion and from the first right cut line to the second rightcut line forms a right side flap separate from the third tear strip, theleft and right side flaps being folded in the reusable envelope alongthe respective fold line portions to close the sides of the reusableenvelope.
 12. The reusable envelope of claim 1, wherein the tear linesare formed by perforations.
 13. The reusable envelope of claim 12,wherein the perforations are slit perforations.
 14. The reusableenvelope of claim 1, wherein the first edge of the second flap panel isa fourth weakened tear line, the reusable envelope further comprising atleast one contents panel including a first contents panel having opposedtransverse third and fourth edges, the first contents panel being joinedat its third edge to the first edge of the second flap panel, the firstcontents panel being within the reusable envelope.
 15. The reusableenvelope of claim 14, further comprising: opposed left and right lateraldefinition lines extending from the second edge of the first flap panelto the fourth edge of the contents panel, the left lateral definitionline being spaced from left lateral edges of at least the first flap andrear panels by a second distance, and the right lateral definition linebeing spaced from right lateral edges of at least the first flap andrear panels by the second distance, wherein a second tear strip isformed of at least areas on the first flap and rear panels between therespective left lateral edges and the left lateral definition line,wherein a third tear strip is formed of at least areas on the first flapand rear panels between the respective right lateral edges and the rightlateral definition line, and wherein at least the first flap and rearpanels are joined along their lateral edges to form the reusableenvelope.
 16. The reusable envelope of claim 14, wherein the at leastone contents panel further includes an additional contents panel joinedto the first contents panel along the fourth edge, the additionalcontents panel being within the reusable envelope.
 17. The reusableenvelope of claim 1, further comprising at least one contents panelincluding a first contents panel having opposed transverse third andfourth edges, the first contents panel being joined at its third edge tothe second edge of the first flap panel, the first contents panel beingwithin the reusable envelope.
 18. The reusable envelope of claim 17,further comprising: opposed left and right lateral definition linesextending from the fourth edge of the contents panel to the first edgeof the second flap panel, the left lateral definition line being spacedfrom left lateral edges of at least the first flap and rear panels by asecond distance, and the right lateral definition line being spaced fromright lateral edges of at least the first flap and rear panels by thesecond distance, wherein a second tear strip is formed of at least areason the first flap and rear panels between the respective left lateraledges and the left lateral definition line, wherein a third tear stripis formed of at least areas on the first flap and rear panels betweenthe respective right lateral edges and the right lateral definitionline, and wherein at least the first flap and rear panels are joinedalong their lateral edges to form the reusable envelope.
 19. Thereusable envelope of claim 17, the at least one contents panel furtherincluding an additional contents panel joined to the first contentspanel along the fourth edge, the additional contents panel being withinthe reusable envelope.
 20. The reusable envelope of claim 1, wherein thedefinition line is a fourth transverse weakened tear line, the firstflap panel being separable from the front panel along the fourth tearline.
 21. The reusable envelope of claim 1, wherein the definition lineis a third transverse fold line, the first flap panel having a fourthtransverse weakened tear line spaced from the third fold line by thefirst distance, the front panel having a fifth transverse weakened tearline spaced from the third fold line by the first distance, and the tearstrip further being formed of an area on the first flap panel betweenthe third fold line and the fourth tear line and an area on the frontpanel between the fifth tear line and the third fold line.
 22. Thereusable envelope of claim 1, wherein the rear panel is similar in sizeto the first flap panel.
 23. The reusable envelope of claim 1, whereinthe rear panel is similar in size to the first flap panel in itstransverse direction and is shorter than the first flap panel in itslengthwise direction by at least the first distance.
 24. The reusableenvelope of claim 1, wherein the second adhesive area bears aremoistenable adhesive.
 25. The reusable envelope of claim 1, whereinthe first adhesive area is a Ushaped area having a top at the top of theenvelope pocket.
 26. A reusable envelope comprising: a plurality ofpanels including first, second and third panels each being generallyrectangular and at least the second and third panels being similar insize, the first panel being joined to the second panel along atransverse definition line and the second panel being joined to thethird panel along a transverse fold line, the second panel having afirst transverse weakened tear line extending entirely across the secondpanel and spaced from the fold line by a predetermined distance todefine a first area between the first tear line and the fold line, andthe third panel having a second transverse weakened tear line extendingentirely across the third panel and spaced from the fold line by thepredetermined distance to define a second area between the second tearline and the fold line, wherein the first panel is folded with respectto the second panel along the definition line, and wherein the secondpanel is folded with respect to the third panel along the fold line suchthat the first and second tear lines are collinear, the first area beingsealed to the second area to define a tear strip that is removable alongthe collinear tear lines to at least partially create a second envelopefor remailing.
 27. The reusable envelope of claim 26, wherein the secondpanel has a third transverse weakened tear line extending entirelyacross the second panel and spaced from the first tear line in adirection away from the fold line by a second predetermined distance todefine a third area between the first tear line and the third tear line,and the third panel has a fourth transverse weakened tear line extendingentirely across the third panel and spaced from the second tear line ina direction away from the fold line by the second predetermined distanceto define a fourth area between the second tear line and the fourth tearline, the third and fourth tear lines being collinear, and the fourtharea being sealed to the third area to define a second tear strip thatis removable along the collinear third and fourth tear lines to open thesecond envelope.
 28. The reusable envelope of claim 26, wherein thedefinition line is a third weakened tear line.
 29. The reusable envelopeof claim 26, wherein the first panel has a transverse edge opposed tothe definition line and a third transverse weakened tear line extendingentirely across the first panel and spaced from the edge by thepredetermined distance to define a third area between the edge and thethird tear line, the third tear line being collinear with the first andsecond tear lines and the third area forming part of the tear strip. 30.The reusable envelope of claim 29, wherein the second panel has a fourthtransverse weakened tear line extending entirely across the second paneland spaced from the first tear line in a direction away from the foldline by a second predetermined distance to define a fourth area from thefirst tear line to the fourth tear line, and the third panel has a fifthtransverse weakened tear line extending entirely across the third paneland spaced from the second tear line in a direction away from the foldline by the second predetermined distance to define a fifth area fromthe second tear line to the fifth tear line, the fourth and fifth tearlines being collinear, and the fourth area being sealed to the fiftharea to define a second tear strip that is removable along the collinearfourth and fifth tear lines to open the second envelope.